Stacked soft magnetic inserts and slotted shield designs for titled coil antennas

ABSTRACT

An antenna assembly includes a tool mandrel having a tool axis, and a coil including a plurality of windings wrapped about the tool mandrel at a winding angle offset from the tool axis. A soft magnetic band radially interposes the coil and the tool mandrel and extends about a circumference of the tool mandrel at a band angle parallel to the winding angle. The soft magnetic band includes a plurality of stacked inserts extending perpendicular to the coil about the circumference of the tool mandrel and each stacked insert includes a plurality of rods positioned end-to-end.

BACKGROUND

During drilling operations for the extraction of hydrocarbons, a varietyof recording and transmission techniques are used to provide or recordreal-time data from the vicinity of a drill bit. Measurements ofsurrounding subterranean formations may be made throughout drillingoperations using downhole measurement and logging tools, such asmeasurement-while-drilling (MWD) tools, which aid in making operationaldecisions, and logging-while-drilling (LWD) tools, which helpcharacterize the formations. LWD tools in particular obtain measurementsused to determine the electrical resistivity (or its inverse,conductivity) of the surrounding subterranean formations beingpenetrated, where the electrical resistivity indicates variousgeological features of the formations. These resistivity measurementsmay be taken using one or more antennas coupled to or otherwiseassociated with the wellbore logging tools. Such data can also beobtained while not drilling, such as in a wireline logging operations.

Logging tool antennae are often formed by positioning coil windingsabout an axial section of the wellbore logging tool, such as a drillcollar. A soft magnetic material is sometimes positioned beneath thecoil windings to increase the efficiency and/or sensitivity of thelogging tool antennae. The soft magnetic material facilitates a highermagnetic permeability path (i.e., a flux conduit) for the magnetic fieldgenerated by the coil windings, and helps shield the coil windings fromadjacent drill collars and associated losses (e.g., eddy currentsgenerated on the drill collars).

BRIEF DESCRIPTION OF THE DRAWINGS

The following figures are included to illustrate certain aspects of thepresent disclosure, and should not be viewed as exclusive embodiments.The subject matter disclosed is capable of considerable modifications,alterations, combinations, and equivalents in form and function, withoutdeparting from the scope of this disclosure.

FIG. 1 is a schematic diagram of an example drilling system that mayemploy the principles of the present disclosure.

FIG. 2 is a schematic diagram of an example wireline system that mayemploy the principles of the present disclosure.

FIG. 3A is a partial isometric view of an example wellbore logging tool.

FIG. 3B is a schematic side view of the magnetic flux from the wellborelogging tool of FIG. 3A.

FIG. 4 depicts a side view of an example antenna assembly.

FIG. 5A depicts a side view of another example embodiment of the antennaassembly of FIG. 4.

FIG. 5B is an isometric view of the soft magnetic band of FIG. 5A.

FIGS. 6A and 6B are isomeric and side views, respectively, of anotherexample embodiment of the antenna assembly of FIG. 4.

FIG. 7A is a side view of an example antenna assembly that incorporatesone or more principles of the present disclosure.

FIG. 7B is a side view of the antenna assembly of FIG. 7A without thecoil.

FIG. 8A is an isometric view of an example bobbin.

FIG. 8B depicts an isometric view of another embodiment of the bobbin ofFIG. 8A.

FIG. 9 is a side view of an antenna assembly that includes an exampleantenna shield.

FIG. 10 is a side view of the antenna assembly of FIG. 9 that includesan embodiment of the antenna shield incorporating one or more principlesof the present disclosure.

FIGS. 11-13 depict test results obtained by varying shield parameters onan antenna assembly.

FIG. 14 is a table showing comparative test results obtained from threevariations in antenna shield designs.

FIG. 15 is a table showing comparative test results obtained from twovariations in antenna shield designs in conjunction with varying thedesign of an underlying soft magnetic band.

FIG. 16 is a table showing comparative test results obtained fromvariations in antenna assembly designs having stacked inserts alignedand misaligned with the slots in an antenna shield.

FIG. 17 is a table showing comparative test results obtained fromvariations in antenna assembly designs having a soft magnetic bandcomprising stacked inserts with varying numbers of rods.

DETAILED DESCRIPTION

The present disclosure relates generally to wellbore logging tools usedin the oil and gas industry and, more particularly, to the design oftilted coil antennas using stacked soft magnetic inserts and innovativeantenna shields that improve gain, sensitivity, and efficiency of thetilted coil antennas.

Embodiments of the present disclosure describe improvements to thedesign of antenna assemblies used in resistivity logging tools formonitoring surrounding subterranean formations adjacent a drilledwellbore. Some of the antenna assemblies described herein include tiltedcoil antennas that include a soft magnetic band to increase theinductance of the tilted coil antenna. In such assemblies, the softmagnetic band includes a plurality of stacked inserts extendingperpendicular to the tilted coil antenna and each stacked insertincludes a plurality of rods positioned end-to-end. The rods included ineach stacked insert are of a simple design and commercially availableand, therefore, help reduce the cost of assembling and maintaining theantenna assemblies as compared to antenna assemblies having softmagnetic bands with inserts that exhibiting complex geometries that aredifficult and expensive to manufacture.

Other antenna assemblies described herein include a tilted coil antennaand an antenna shield positioned radially outward from the tilted coilantenna. The antenna shield defines a plurality of slots extendingperpendicular to the windings of the tilted coil antenna and theplurality of slots is provided in two or more dissimilar lengths. Thedissimilar lengths for the slots not only support operation of theantenna assemblies by minimizing attenuation of electromagnetic fieldsand preserving the dipole orientation of the tilted coil antenna, butalso in preserving the mechanical integrity and strength to protect thetilted coil antenna.

FIG. 1 is a schematic diagram of an example drilling system 100 that mayemploy the principles of the present disclosure, according to one ormore embodiments. As illustrated, the drilling system 100 may include adrilling platform 102 positioned at the surface and a wellbore 104 thatextends from the drilling platform 102 into one or more subterraneanformations 106. In other embodiments, such as in an offshore drillingoperation, a volume of water may separate the drilling platform 102 andthe wellbore 104.

The drilling system 100 may include a derrick 108 supported by thedrilling platform 102 and having a traveling block 110 for raising andlowering a drill string 112. A kelly 114 may support the drill string112 as it is lowered through a rotary table 116. A drill bit 118 may becoupled to the drill string 112 and driven by a downhole motor and/or byrotation of the drill string 112 by the rotary table 116. As the drillbit 118 rotates, it creates the wellbore 104, which penetrates thesubterranean formations 106. A pump 120 may circulate drilling fluidthrough a feed pipe 122 and the kelly 114, downhole through the interiorof drill string 112, through orifices in the drill bit 118, back to thesurface via the annulus defined around drill string 112, and into aretention pit 124. The drilling fluid cools the drill bit 118 duringoperation and transports cuttings from the wellbore 104 into theretention pit 124.

The drilling system 100 may further include a bottom hole assembly (BHA)coupled to the drill string 112 near the drill bit 118. The BHA maycomprise various downhole measurement tools such as, but not limited to,measurement-while-drilling (MWD) and logging-while-drilling (LWD) tools,which may be configured to take downhole measurements of drillingconditions. The MWD and LWD tools may include at least one resistivitylogging tool 126, which may comprise one or more antennas capable ofreceiving and/or transmitting one or more electromagnetic (EM) signalsthat are axially spaced along the length of the resistivity logging tool126. As described below, the resistivity logging tool 126 may furthercomprise a plurality of stacked soft magnetic inserts used to enhanceand/or shield the EM signals and thereby increase the azimuthalsensitivity of the resistivity logging tool 126.

As the drill bit 118 extends the wellbore 104 through the formations106, the resistivity logging tool 126 may continuously or intermittentlycollect azimuthally-sensitive measurements relating to the resistivityof the formations 106, i.e., how strongly the formations 106 opposes aflow of electric current. The resistivity logging tool 126 and othersensors of the MWD and LWD tools may be communicably coupled to atelemetry module 128 used to transfer measurements and signals from theBHA to a surface receiver (not shown) and/or to receive commands fromthe surface receiver. The telemetry module 128 may encompass any knownmeans of downhole communication including, but not limited to, a mudpulse telemetry system, an acoustic telemetry system, a wiredcommunications system, a wireless communications system, or anycombination thereof. In certain embodiments, some or all of themeasurements taken at the resistivity logging tool 126 may also bestored within the resistivity logging tool 126 or the telemetry module128 for later retrieval at the surface upon retracting the drill string112.

At various times during the drilling process, the drill string 112 maybe removed from the wellbore 104, as shown in FIG. 2, to conductmeasurement/logging operations. More particularly, FIG. 2 depicts aschematic diagram of an example wireline system 200 that may employ theprinciples of the present disclosure, according to one or moreembodiments. Like numerals used in FIGS. 1 and 2 refer to the samecomponents or elements and, therefore, may not be described again indetail. As illustrated, the wireline system 200 may include a wirelineinstrument sonde 202 that may be suspended in the wellbore 104 on acable 204. The sonde 202 may include the resistivity logging tool 126described above, which may be communicably coupled to the cable 204. Thecable 204 may include conductors for transporting power to the sonde 202and also facilitate communication between the surface and the sonde 202.A logging facility 206, shown in FIG. 2 as a truck, may collectmeasurements from the resistivity logging tool 126, and may includecomputing and data acquisition systems 208 for controlling, processing,storing, and/or visualizing the measurements gathered by the resistivitylogging tool 126. The computing and data acquisition systems 208 may becommunicably coupled to the resistivity logging tool 126 by way of thecable 204.

FIG. 3A is a partial isometric view of an example wellbore logging tool300, according to one or more embodiments. The logging tool 300 may bethe same as or similar to the resistivity logging tool 126 of FIGS. 1and 2 and, therefore, may be used in the drilling or wireline systems100, 200 depicted therein. The wellbore logging tool 300 is depicted asincluding an antenna assembly 302 that can be positioned about a toolmandrel 304, such as a drill collar or the like. The antenna assembly302 may include a bobbin 306 and a coil 308 wrapped about the bobbin 306and extending axially by virtue of winding along at least a portion ofan outer surface of the bobbin 306.

The bobbin 306 may structurally comprise a high temperature plastic, athermoplastic, a polymer (e.g., polyimide), a ceramic, or an epoxymaterial, but could alternatively be made of a variety of othernon-magnetic, electrically insulating/non-conductive materials. Thebobbin 306 can be fabricated, for example, by additive manufacturing(i.e., 3D printing), molding, injection molding, machining, or otherknown manufacturing processes.

The coil 308 can include any number of consecutive “turns” (i.e.windings of the coil 308) about the bobbin 306, but typically willinclude at least a plurality (i.e. two or more) consecutive full turns,with each full turn extending 360° about the bobbin 306. In someembodiments, a pathway for receiving the coil 308 may be formed alongthe outer surface of the bobbin 306. For example, one or more grooves orchannels may be defined in the outer surface of the bobbin 306 toreceive and seat the coil 308. In other embodiments, however, the outersurface of the bobbin 306 may be smooth or even. The coil 308 can beconcentric or eccentric relative to a tool axis 310 of the tool mandrel304.

As illustrated, a portion of the turns or windings of the coil 308extend about the bobbin 306 at a winding angle 312 offset relative tothe tool axis 310. More specifically, the windings of the coil 308 onopposing sides of the bobbin 306 extend about the outer circumference ofthe bobbin 306 at the winding angle 312. The windings, however,transition to perpendicular to the tool axis 310 at the top and bottomof the bobbin 306, at which point the windings transition back to thewinding angle 312 on opposing sides of the bobbin 306. Successivewindings of the coil 308 (i.e., one or more successive revolutions ofthe coil 308) advance in a generally axial direction along at least aportion of the outer surface of the bobbin 306 such that coil 308 spansan axial length of the bobbin 308. The antenna assembly 302 may becharacterized and otherwise referred to as a “tilted coil” or“directional” antenna. In the illustrated embodiment, the winding angle312 is 45°, by way of example, and could alternatively be any angleoffset relative to the tool axis 310, without departing from the scopeof the disclosure.

FIG. 3B is a schematic side view of the wellbore logging tool 300 ofFIG. 3A. When current is passed through the coil 308 of the antennaassembly 302, a dipole magnetic field 314 may be generated that extendsradially outward from the antenna assembly 302 orthogonal to the windingdirection. As a result, the antenna assembly 302 may exhibit a magneticfield angle 316 with respect to the tool mandrel 304 and, since thewinding angle 312 (FIG. 3A) is 45°, the resulting magnetic field angle316 will also be 45° offset from the tool axis 310. As will beappreciated, however, the magnetic field angle 316 may be varied byadjusting or manipulating the winding angle 312.

FIG. 4 depicts a side view of an example antenna assembly 402. Theantenna assembly 402 may be similar in some respects to the antennaassembly 302 of FIGS. 3A-3B and, therefore, may be best understood withreference thereto, where like numerals represent like element notdescribed again. As illustrated, the antenna assembly 402 includes thecoil 308 wrapped about the tool mandrel 304 and, more particularly,within a saddle 404 defined on the tool mandrel 304. The saddle 404 maycomprise a portion of the tool mandrel 304 that exhibits areduced-diameter as compared to the remaining portions of the toolmandrel 304. Some or all of the components of the antenna assembly 402may be arranged within the saddle 404. While not shown in thisembodiment, the bobbin 306 (FIG. 3A) may alternatively be included tointerpose the coil 308 and the tool mandrel 304 (i.e., the saddle 404),as generally discussed above.

As illustrated, the windings of the coil 308 extend about thecircumference of the tool mandrel 304 at the winding angle 312, whichmay be offset from the tool axis 310, for example, by 45°. As a result,the magnetic dipole moment 316 generated by the coil 308 may extend fromthe tool mandrel 304 at the magnetic field angle 318, which isorthogonal to the winding angle 312 of the coil 308. The directionalityof the magnetic dipole moment 316 may generally correspond to thedirection in which the coil 308 emits the dipole magnetic field 314(FIG. 3B) when current is passed therethrough. In some applications, itmay be desired for best results to have the magnetic dipole moment 316offset from the tool axis 310 by 45°, but the magnetic field angle 318could alternatively be any angle between parallel and perpendicular tothe tool axis 310 because of effects caused by the tool mandrel 304 oras a result of using a soft magnetic band, as described below.

FIG. 5A depicts another embodiment of the antenna assembly 402. In theillustrated embodiment, a soft magnetic band 502 interposes the coil 308and the tool mandrel 304 within the saddle 404. The soft magnetic band502 may be configured to shield the coil winding 308 from eddy currentsgenerated by the tool mandrel 304, thereby increasing the azimuthalsensitivity of the antenna assembly 402 and/or increasing the efficiencyor strength of the dipole magnetic field 314 (FIG. 3B) of the coil 308.

To facilitate this effect, the soft magnetic band 502 may comprise asoft magnetic material or any material that exhibits relatively highresistivity, high magnetic permeability, and low magnetic loss (e.g.,hysteresis, magnetostriction, etc.). One suitable soft magnetic materialthat may be used includes ferrites, which generally comprise a compositemixture of a powder iron/ferrite material and a binder, such as asilicone-based rubber, an elastomer, an RTV, a polymer (such aspolyimide), a ceramic, or an epoxy. The resulting mixture is moldedand/or pressed into desired geometric shapes and configurations thatconform to the shape of the soft magnetic band 502. Other suitable softmagnetic materials that may be used in the soft magnetic band 502include, but are not limited to, mu-metal, permalloy, metallic glass(metglass), or any combination of the foregoing.

The soft magnetic band 502 may comprise a generally annular ring thatextends about the circumference of the tool mandrel 304 (e.g., withinthe saddle 404) at a band angle 504. In the illustrated embodiment, theband angle 504 and the winding angle 312 are substantially the same suchthat the soft magnetic band 502 interposes the coil 308 and the toolmandrel 304 about the corresponding circumference of the tool mandrel304. To help maintain the directionality of the magnetic dipole moment316 at 45° relative to the tool axis 310, the soft magnetic band 502 maycomprise a plurality of strips or inserts 506. Accordingly, in theillustrated example, the soft magnetic band 502 comprises a plurality ofinserts 506 that form a discontinuous annular ring extending about thecircumference of the tool mandrel 304 at the band angle 504. Asillustrated, the band angle 504 and the winding angle 312 aresubstantially parallel, but could alternatively be offset from parallelby +/−10°, without departing from the scope of the disclosure.

FIG. 5B is an isometric view of the soft magnetic band 502 of FIG. 5A.As illustrated, the inserts 506 exhibit a tilted cut shape and,therefore, may be referred to as “tilted” inserts 506. Moreover, theinserts 506 are cut and otherwise formed axially and otherwise parallelto the tool axis 310. Each insert 506 may be separated from angularlyadjacent inserts by a small gap 508 that prevents physical contactbetween angularly adjacent inserts 506, and thereby prevents acontinuous magnetic path between the adjacent inserts 506. In someembodiments, the gap 508 may be filled with a material that exhibits arelative permeability (μ_(r)) of approximately 1, which is equivalent tothe permeability of free space or air (μ_(o)). In such embodiments, forexample, the inserts 506 may be positioned (inserted) withincorresponding channels defined in the bobbin 306 (FIG. 3A) where the gap508 is filled by separators provided by the bobbin 306. In otherembodiments, the gap 508 may not be filled with any particular materialbut may instead allow air to separate the adjacent inserts 506. In anycase, the gap 508 essentially serves as a non-magnetic insulator betweenthe adjacent inserts 506.

As illustrated, the inserts 506 comprise generally rectangular orparallelogram-shaped members (depending on where angularly located aboutthe circumference of the tool mandrel 304) separated by the gap 508.Each insert 506 may have a length 510 a and a width 510 b, where thelength 510 a of each axially cut insert 506 extends substantiallyparallel to the tool axis 310. As a result, the gap 508 separating eachlaterally adjacent insert 506 may be aligned axially with the tool axis310 and otherwise run parallel thereto. Moreover, each insert 506 mayexhibit an arcuate shape across (along) the width that conforms to thecurvature of the tool mandrel 304 (FIG. 5A) and/or the saddle 404 (FIG.5A).

Referring now to FIGS. 6A and 6B, illustrated are isometric and sideviews, respectively, of another example embodiment of the antennaassembly 402. Similar to the embodiments of FIGS. 4 and 5A-5B, theantenna assembly 402 includes the coil 308 wrapped about the toolmandrel 304 and, in some embodiments, positioned within the saddle 404.The windings of the coil 308 extend about the tool mandrel 304 at thewinding angle 312 (FIG. 6B), which, as noted above, may be angularlyoffset from the tool axis 310 (FIG. 6B) by 45°, but could alternativelybe any angle offset from the tool axis 310. As a result, the magneticdipole moment 316 (FIG. 6B) generated by the coil 308 may extend fromthe tool mandrel 304 at the magnetic field angle 318 (FIG. 6B), which isorthogonal to the winding angle 312.

Similar to the embodiment of FIGS. 5A-5B, the soft magnetic band 502radially interposes the coil 308 and the tool mandrel 304 (e.g., thesaddle 404), and the inserts 506 are separated by the gaps 508 (FIG.6A), which extend substantially parallel to the tool axis 310. Unlikethe embodiment of FIGS. 5A-5B, however, the soft magnetic band 502extends about the circumference of the tool mandrel 304 (e.g., thesaddle 404) at a band angle 602 (FIG. 6B) that is orthogonal to thewinding angle 312. Accordingly, the soft magnetic band 502 may not onlybe characterized as “tilted” with respect to the tool axis 310, but mayalso be referred to as a “reversed” soft magnetic band. In embodimentswhere the winding angle 312 is 45° offset from the tool axis 310, theband angle 602 may also be 45° offset from the tool axis 310, butangularly opposite the winding angle 312 along the tool axis 310 (i.e.,90° offset from the winding angle 312). Since the coil 308 and the softmagnetic band 502 are each wrapped about the circumference of the toolmandrel 304 in orthogonal directions, at least a portion of the coil 308extends axially past the soft magnetic band 502 where the soft magneticband 502 does not radially interpose the coil 308 and the tool mandrel304.

Each insert 506 of the soft magnetic band 502 exhibits a uniquecross-section that must conform to the curvature of the tool mandrel 304and/or the saddle 404. Consequently, it can be difficult and expensiveto manufacture the inserts 506 since each insert 506 has to be custommade, which increases the overall manufacturing and assembling costs forthe antenna assembly 402. According to one or more embodiments of thepresent disclosure, soft magnetic band inserts that are difficult tomanufacture on account of requiring complex geometries can be replacedwith inexpensive, commercially available (i.e., off-the-shelf) softmagnetic band inserts that exhibit a simple geometry. As discussedbelow, using such commercially available soft magnetic band inserts withsimple geometry can achieve the same or better antenna performance ascompared to the embodiment of FIGS. 6A-6B.

FIG. 7A is a side view of an example antenna assembly 702 thatincorporates one or more principles of the present disclosure. Theantenna assembly 702 may be similar in some respects to the embodimentsof the antenna assembly 402 shown in FIGS. 4, 5A-5B, and 6A-6B and,therefore, may be best understood with reference thereto, where similarnumerals refer to like elements or components not described again.Similar to the embodiments of the antenna assembly 402, for example, theantenna assembly 702 includes the coil 308 wrapped about the toolmandrel 304 and, in at least some embodiments, positioned within thesaddle 404. The windings of the coil 308 extend about the tool mandrel304 at the winding angle 312, which, as noted above, may be angularlyoffset from the tool axis 310 by 45°, but could alternatively be anyangle offset from the tool axis 310. As a result, the magnetic dipolemoment 316 generated by the coil 308 extends from the tool mandrel 304at the magnetic field angle 318, which is orthogonal to the windingangle 312. While the coil 308 is depicted as having only fourconsecutive windings, it will be appreciated that more or less than fourwindings may be employed in the antenna assembly 702, without departingfrom the scope of the disclosure.

The antenna assembly 702 also includes a soft magnetic band 704 thatradially interposes the coil 308 and the tool mandrel 304 (e.g., thesaddle 404). FIG. 7B is a side view of the antenna assembly 702 of FIG.7A excluding the coil 308 to facilitate a better view of the novelfeatures of the soft magnetic band 704. In the illustrated embodiment,the soft magnetic band 704 comprises a plurality of stacked inserts 706angularly offset from each other to form a discontinuous annular ringthat extends about the circumference of the tool mandrel 304 (e.g.,within the saddle 404) at the band angle 504. The band angle 504 and thewinding angle 312 (FIG. 7A) are substantially the same such that thesoft magnetic band 704 interposes the coil 308 and the tool mandrel 304about the entire circumference of the tool mandrel 304.

Each stacked insert 706 is separated from angularly adjacent stackedinserts by a gap 708, which is similar to the gap 508 discussed abovewith reference to FIGS. 4, 5A-5B, and 6A-6B. Accordingly, the gaps 708prevent physical contact between angularly adjacent stacked inserts 706.

As illustrated, each stacked insert 706 includes a plurality of rods 710(alternately referred to as “units”) arranged and otherwise positionedend-to-end (i.e., “stacked”) to cooperatively form a straight orsubstantially straight stacked insert 706. The rods 710 may be made ofany of the soft magnetic materials mentioned herein with respect to thesoft magnetic band 502 of FIGS. 5A-5B and 6A-6B including, but notlimited to, ferrite, mu-metal, permalloy, metallic glass (metglass), orany combination thereof. In some embodiments, as illustrated, three rods710 may be arranged end-to-end to jointly (mutually) form a givenstacked insert 706. In other embodiments, however, more or less thanthree rods 710 (at least two) may be arranged end-to-end to form a givenstacked insert 706. Moreover, in some embodiments, a small gap may beformed between opposing ends of the rods 710. In other embodiments,however, the opposing ends of one or more of the rods 710 in a givenstacked insert 706 may come into contact and otherwise directly toucheach other.

The rods 710 of each stacked insert 706 are arranged such that thestacked insert 706 extends substantially perpendicular to the windingsof the radially adjacent coil 308 (FIG. 7A) at any given angularlocation about the circumference of the tool mandrel 304. As a result,the soft magnetic band 704 helps to maintain the directionality of themagnetic dipole moment 316 (FIG. 7A) at 45° relative to the tool axis310 (FIG. 7A). As used herein, the phrase “substantially perpendicular”refers to a 90° relative offset between the stacked insert 706 and thewindings of the radially adjacent coil 308, but also encompasses a+/−10° offset from perpendicular, without departing from the scope ofthe disclosure.

The rods 710 of each stacked insert 706 may comprise straight,cylindrical members that provide a circular or polygonal cross-section.In other words, each rod 710 may exhibit a cross-sectional shape that iscircular, such as rounded, oval, or ovoid, or alternatively across-sectional shape that is polygonal, such as, triangular,rectangular (including square), pentagonal, etc. In the illustratedexample the rods 710 are depicted as cylindrical members with apolygonal (e.g., rectangular) cross-section. In some embodiments, agiven stacked insert 706 may comprise rods 710 having dissimilarcross-sectional shapes, without departing from the scope of thedisclosure.

Each rod 710 may have a length 712 that contributes to the total length714 of the corresponding stacked insert 706. The length 712 of a givenrod 710 may or may not be the same as the length 712 of other rod(s) 710in a corresponding stacked insert 706. For example, the length 712 ofany of the rods 710 can range between about 1.0 inch and 5.0 inches, butcould alternatively be shorter than 1.0 inch or longer than 5.0 inches,without departing from the scope of the disclosure. In at least oneembodiment, the length 712 of the rods 710 will be less than half of theelliptical circumferences of the tool mandrel 304 (e.g., the saddle 404)along the designed path of the stacked inserts 706. Consequently, insuch embodiments, the range of the length 712 of the rods 710 maydepends on the diameter of the tool mandrel 304 (e.g., within the saddle404). The relatively short length 712 of the rods 710 allows thecorresponding stacked insert 706 to roughly but substantially follow thecurvature of the outer surface of the tool mandrel 304 (e.g., the saddle404) as it extends perpendicular to the coil 308.

The rods 710 may be commercially available as an off-the-shelf item andmay comprise standard sizes that can be purchased in the market from avariety of manufacturers and/or outlets. For example, the rods 710 maybe purchased from CWS Bytemark of Orange, Calif., USA, or DexterMagnetic Technologies, Inc. of Elk Grove Village, Ill., USA. As will beappreciated, using commercially available rods 710 to form the stackedinserts 706 may reduce costs in assembling and maintaining the antennaassembly 702 as compared to conventional or prior antenna assemblieswhere the soft magnetic band comprises inserts exhibiting complexgeometries that are difficult and expensive to manufacture. For example,prior art soft magnetic bands can cost as much as US $20 k per antenna,while soft magnetic bands using the stacked inserts 706 described hereinmay cost only US $100 per antenna. Moreover, as discussed below,employing the stacked inserts 706 may provide similar or better gainperformance as compared to conventional or prior antenna assemblies withcustom-made soft magnetic bands.

FIG. 8A depicts an isometric view of an example bobbin 802, according toone or more embodiments of the present disclosure. The bobbin 802 may bethe same as or similar to the bobbin 306 described above with referenceto FIG. 3A and, therefore, may be made of similar materials mentionedherein. While the stacked inserts 706 of the soft magnetic band 704 ofFIGS. 7A and 7B are shown positioned about the outer circumference ofthe mandrel 304 (e.g., the saddle 404), the stacked inserts 706 mayalternatively be positioned on and otherwise attached to the bobbin 802.In turn, the bobbin 802 may be positioned about the outer circumferenceof the mandrel 304, such as within the saddle 404. In the illustratedembodiment, for example, the bobbin 802 may have a plurality of groovesor channels 804 defined on its inner radial surface 806. Each channel804 may be sized and otherwise configured to receive a single stackedinsert 706 (FIG. 7B). In such embodiments, the coil 308 (FIG. 7A) wouldbe wound about the outer radial surface 808 of the bobbin 802.

FIG. 8B depicts an isometric view of another embodiment of the bobbin802 of FIG. 8A. In FIG. 8B, the stacked inserts 706 are shown arrangedon the outer radial surface 808 of the bobbin 802. In at least oneembodiment, the stacked inserts 706 may be at least partially receivedwithin corresponding channels 810 defined in the outer radial surface808 of the bobbin 802. In other embodiments, however, the outer radialsurface 808 of the bobbin 802 may be smooth and the stacked inserts 706may alternatively be arranged directly on the outer radial surface 808.In such embodiments, the coil 308 (FIG. 7A) may be wound about the outerradial surface 808 of the bobbin 802 but radially supported by thestacked inserts 706.

Referring again to FIG. 7A, it may be desired to protect the antennaassembly 702 (especially the coil 308) from mechanical or operationaldamage during use. For example, an unprotected (unshielded) coil 308 maybe damaged during wellbore drilling operations through prolongedexposure to wellbore cuttings and debris or by extensive contact with awellbore wall as an associated drill string is moved within thewellbore. In some embodiments, the coil 308 may be protected frommechanical damage by covering or otherwise coating all or a portion ofthe antenna assembly 702 with a non-magnetic, electricallyinsulating/non-conductive material such as, but not limited to, apolymer (e.g., PEEK), a polymer-ceramic blend, or a ceramic. Thismaterial may be added (deposited), for example, within the reduceddiameter portion of the tool mandrel 304 defined by the saddle 404. Thematerial is electrically resistive and, therefore, can protect theantenna assembly 702 while not attenuating the electromagnetic fieldstransmitted or received.

In other embodiments, however, the coil 308 may be protected frommechanical damage by using or otherwise installing an antenna shieldthat axially spans the reduced diameter portion of the tool mandrel 304defined by the saddle 404 and effectively covers the coil 308. Theantenna shield may be electromagnetically transmissive to allowtransmission of electromagnetic signals. In some embodiments, theelectromagnetic transmissivity of the antenna shield may be achieved byproviding slots defined through the body of the antenna shield.

FIG. 9 is a side view of an antenna assembly 902 that includes anexample antenna shield 906 used to protect the antenna assembly 902(especially the underlying coil 308). The antenna assembly 902 may bethe same as or similar to any of the antenna assemblies 402 (FIGS. 4,5A-5B, and 6A-6B) and 702 (FIGS. 7A-7B) described herein and, therefore,may be best understood with reference thereto, where similar numeralsrefer to like elements or components not described again. The antennaassembly 902, for example, includes the coil 308 wrapped about the toolmandrel 304 and, in at least some embodiments, positioned within thesaddle 404 (shown in dashed lines). The windings of the coil 308 extendabout the tool mandrel 304 at the winding angle 312.

The antenna assembly 902 also includes a soft magnetic band 904 radiallyinterposing the coil 308 and the tool mandrel 304 (e.g., the saddle404). In the illustrated embodiment, the soft magnetic band 904 issimilar to the soft magnetic band 704 of FIGS. 7A-7B, but couldalternatively comprise any of the soft magnetic band embodimentsdiscussed herein or other soft magnetic band designs and configurationsaltogether, without departing from the scope of the disclosure.

The antenna shield 906 provides a circumferential encapsulation of theinternal components of the antenna assembly 902 by extending about thetool axis 310. More specifically, the antenna shield 906 is positionedradially outward from the coil 308 and the soft magnetic band 904. Asillustrated, the antenna shield 906 can axially span the axial length ofthe saddle 404 and is secured to (or otherwise engages) the tool mandrel304 at its opposing axial ends. In some embodiments, the antenna shield906 may be designed such that a relatively smooth structural transitionis achieved between the antenna shield 906 and the outer diameter of thetool mandrel 304 at the opposing axial ends of the antenna shield 906.

In some embodiments, the antenna shield 906 can be formed of anon-conductive and/or non-metallic material, such as fiberglass or apolymer (e.g., polyether ether ketone or “PEEK”). In other embodiments,however, the antenna shield 906 can be made of a conductive and/ormetallic material, such as stainless steel, a nickel-based alloy (e.g.,MONEL®, INCONEL®, etc.), a chromium-based alloy, a copper-based alloy,or any combination thereof.

The antenna shield 906 also includes a plurality of slots 908 definedthrough the body of the antenna shield 906. The slots 908 facilitateelectromagnetic transmissivity of the antenna shield 906 by providingareas where electromagnetic signals can penetrate the antenna shield 906to be received or transmitted. In the illustrated embodiment, each slot908 is formed in the shape of a rectangle, but could alternativelyexhibit other shapes, without departing from the scope of thedisclosure. Each slot 908 has a length 910 and a width 912, and isseparated from angularly adjacent slots 908 by a separation gap 914. Theseparation gap 914 may or may not be uniform between all angularlyadjacent slots 908. The slots 908 are formed in the antenna shield 906such that each slot 908 extends perpendicular or substantiallyperpendicular to the radially adjacent coil 308 at any given angularlocation about the circumference of the tool mandrel 304. Consequently,the length 910 of each slot 908 extends perpendicular to the radiallyadjacent windings of the coil 308. As used herein, the phrase“substantially perpendicular” refers to a 90° relative offset betweenthe slots 908 and the radially adjacent coil 308, but also encompasses a+/−10° offset from a truly perpendicular relationship, without departingfrom the scope of the disclosure.

In the illustrated embodiment, the length 910 of each slot 908 isconstant (the same) and the pattern of the slots 908 (including themagnitude of the separation gaps 914) is constant about the entirecircumference of the antenna shield 906. The slots 908 cooperativelyform a discontinuous annular ring that extends about the circumferenceof the antenna shield 906 at a slot angle 916. The slot angle 916 andthe winding angle 312 are substantially the same such that the slots 908are arranged radially outward from the coil 308 at any given angularlocation about the circumference of the tool mandrel 304.

The slots 908 help reduce the gain loss from the antenna shield 906,while also reserving the winding (tilt) angle 312 of the coil 308. Theslots 908 of FIG. 9, however, are not optimized to provide maximum gainwhile maintaining acceptable mechanical integrity and strength for theantenna shield 906. Rather, the slot design shown in FIG. 9 constitutesa uniform pattern of similarly sized and arranged slots 908 about thecircumference of the antenna shield 906.

FIG. 10 is a side view of the antenna assembly 902 that includes anembodiment of the antenna shield 906 that incorporates one or moreprinciples of the present disclosure. As will be discussed below, oneway to increase the gain sensitivity of the antenna assembly 902 is toincrease the length of the slots 908 in the antenna shield 906. However,due to mechanical constraints of the structure of the antenna shield906, it is prohibitive to simply increase the length of all the slots908 to a maximum, which might adversely affect the structural integrityof the antenna shield 906 and render it unsuitable for downhole use.

Similar to the embodiment of FIG. 9, each slot 908 of the antenna shield906 of FIG. 10 is separated from angularly adjacent slots 908 by theseparation gap 914. Unlike the embodiment of FIG. 9, however, the slots908 of the antenna shield 906 of FIG. 10 are defined and otherwiseprovided in at least two dissimilar lengths extending perpendicular tothe winding angle 312 (FIG. 9). More specifically, as illustrated, oneor more slots 908 exhibit a first length 1002 a and one or moreadditional (other) slots 908 exhibit a second length 1002 b, where thefirst length 1002 a is longer than the second length 1002 b. Themagnitude (size) of the first and second lengths 1002 a,b may depend onthe material used for the antenna shield, the axial length of the coil308, and other structural parameters of the antenna shield 906. Havingat least two dissimilar lengths 1002 a,b helps minimize the gain lossthrough the antenna shield 906 but also maintains the structuralintegrity and strength of the antenna shield 906.

In principle, and based on conclusions derived from the tests shown inFIGS. 11-13, the slots 908 having the first length 1002 a should be aslong as possible under the condition that all such slots 908 should notmerge at one end and otherwise maintain a minimum distance at one end.The slots 908 having the second length 1002 b may interpose the longerslots 908 and may also be as long as possible under the condition thatall such slots 908 should not merge with the longer slots 908 and alsomaintain a minimum distance between the longer slots 908.

In some embodiments, as illustrated, the slots 908 may be defined(arranged) in a slot pattern where the first and second lengths 1002 a,balternate about the circumference of the antenna shield 906 in aone-to-one ratio. More particularly, a slot 908 having the second length1002 b interposes each angularly adjacent pair of slots 908 having thefirst length 1002 a, or vice versa, where a slot 908 having the firstlength 1002 a interposes each angularly adjacent pair of slots 908having the second length 1002 b.

In other embodiments, however, the slots 908 may be defined in a slotpattern where the first and second lengths 1002 a,b alternate about thecircumference of the antenna shield 906 in a two-to-two ratio. In suchembodiments, two slots 908 having the first length 1002 a may besucceeded by two slots 908 having the second length 1002 b in acontinuous alternating pattern about the circumference of the antennashield 906.

In yet other embodiments, the slots 908 may be defined in a slot patternwhere the first and second lengths 1002 a,b alternate about thecircumference of the antenna shield 906 in a two-to-one ratio. In suchembodiments, two or more slots 908 having the second length 1002 b mayinterpose each angularly adjacent pair of slots 908 having the firstlength 1002 a, or vice versa. In even further embodiments, it iscontemplated herein that the slots 908 having the first and secondlengths 1002 a,b may be provided in a random slot pattern that may ormay not repeat about the circumference of the antenna shield 906.

While the antenna shield 906 of FIG. 10 shows slots 908 having only twodissimilar lengths 1002 a,b, it is contemplated herein that the antennashield 906 provide slots 908 having three or more dissimilar lengths. Insuch embodiments, the pattern of the slots 908 having three or moredissimilar lengths may be uniform and repeat about the circumference ofthe antenna shield 906, or may otherwise be provided in a random patternthat may or may not repeat, without departing from the scope of thedisclosure.

In any of the slot pattern scenarios described herein, the separationgap 914 between angularly adjacent slots 908 of any length 1002 a,b maybe uniform or instead vary about the circumference of the antenna shield906, without departing from the scope of the disclosure.

The soft magnetic band 904 at least partially visible through the slots908 in the antenna shield 906 of FIG. 10 may comprise the soft magneticband 704 of FIGS. 7A-7B. Accordingly, the soft magnetic band 904 mayinclude the plurality of stacked inserts 706 (FIGS. 7A-7B) extendingperpendicular to the coil 308, and simultaneously extending parallel tothe slots 908. In some embodiments, the gap 708 (FIGS. 7A-7B) separatingeach stacked insert 706 from angularly adjacent stacked inserts may havethe same or similar magnitude (size) as the separation gap 914 thatseparates angularly adjacent slots 908. In such embodiments, eachstacked insert 706 may be arranged such that they align radially with acorresponding slot 908. In other embodiments, however, the stackedinserts 706 may be radially misaligned with the slots 908, withoutdeparting from the scope of the disclosure.

Altering different parameters of the antenna shield 906 affects the gainsensitivity of the antenna assembly 902. Example shield parameters thatcan be altered (manipulated) to increase the gain sensitivity of theantenna assembly 902 include, but are not limited to, the number ofslots 908 included in the antenna shield 906, the width 912 (FIG. 9) ofeach slot 908, and the length 916 (FIG. 9) of each slot 908. Throughtesting, the inventors have determined that the most efficient way toincrease the gain sensitivity of the antenna assembly 902 is to maximizethe length 916 of the slots 908. FIGS. 11-13 graphically depict testingdata that supports this conclusion.

More particularly, FIGS. 11-13 depict test results obtained by varyingthe aforementioned shield parameters on an antenna assembly similar tothe antenna assembly 402 of FIGS. 6A-6B and with the antenna shieldsimilar to the antenna shield 906 of FIG. 9. Tests were performed whileexciting the coil 308 (FIGS. 6A-6B) of the antenna assembly 402 atseveral frequencies: 500 Hz, 1 kHz, 2 kHz, 8 kHz, and 32 kHz.

FIG. 11 provides a series of plots depicting test data resulting fromincreasing the number of slots defined in the antenna shield. Data wereobtained from two dissimilar slot designs: 1) slots having a length of4.125 inches (in.) and a width of 0.188 in., and 2) slots having alength of 4.125 in. and a width of 0.250 in. As shown in the plots ofFIG. 11, increasing the number of slots in the antenna shield results ina corresponding increase of gain percentage sensitivity.

FIG. 12 provides a series of plots depicting test data resulting fromincreasing the width of the slots defined in the antenna shield. Datawere obtained from three antenna shield designs: 1) an antenna shieldwith twelve slots having a length of 4.125 in., 2) an antenna shieldwith twenty-four slots having a length of 4.125 in., and 3) an antennashield with twelve slots having a length of 7.500 in. As shown in theplots of FIG. 12, increasing the width of the slots in a given antennashield results in a corresponding increase of gain percentagesensitivity.

FIG. 13 provides a series of plots depicting test data resulting fromincreasing the length of the slots defined in the antenna shield. Datawere obtained from one antenna shield design that including twelve slotshaving a width of 0.188 in. As shown in the plots of FIG. 13, increasingthe length of the slots in the antenna shield results in a correspondingincrease of gain percentage sensitivity.

The data and findings from FIGS. 11-13 are summarized in the followingTable 1:

TABLE 1 Shield Parameter Frequency Range Gain Improvement Doubling # ofSlots 500 Hz → 2 kH ~3%-~7% (12 → 24)  8 kHz → 32 kH ~10% Doubling Widthof Slots 500 Hz → 2 kH ~1%-~2% (0.125 in. → 0.250 in.)  2 kHz → 32 kH~3%-~7% Doubling Length of Slots 500 Hz → 1 kH ~38% (0.4 in. → 0.8 in.) 2 kHz → 32 kH ~50%

From Table 1, it can be concluded that the most efficient way toincrease the gain sensitivity of an antenna assembly is to maximize thelength of the slots defined in the antenna shield.

FIG. 14 is a table 1400 showing comparative test results obtained fromthree variations in antenna shield designs applied to the same antennaassembly. Tests were performed while exciting the coil of each antennaassembly at several frequencies: 500 Hz, 1 kHz, 2 kHz, 8 kHz, and 32kHz. The antenna shield designs are compared against a dipole responsefor an air coil antenna, as shown in the second column. The air coilantenna is a coil antenna operating without an accompanying toolmandrel, soft magnetic band, or antenna shield and the dipole responseresults from coil excitation. The gain for the air coil antenna(magnetic dipole) is used as reference to calculate the gain percentageof the other antenna designs (Gain=Gain_(Design)/Gain_(Dipole)). Asshown in the results of the first column, the dipole response at eachfrequency is 1.

The antenna shield designs are further compared against performance of abase first antenna assembly without an antenna shield, as shown in thethird column. The first antenna assembly is the same as the antennaassembly 402 of FIGS. 6A-6B, and is used as the base antenna assemblyfor each of the second, third, and fourth antenna assemblies.

The second antenna assembly includes an antenna shield that issubstantially similar to the antenna shield 906 of FIG. 9, whichincludes a plurality of tilted slots each having a length of length of4.125 in. and a width of 0.188 in. The third antenna assembly includesan antenna shield having twelve tilted slots, where each slot has alength of length of 7.5 in. and a width of 0.188 in. The fourth antennaassembly includes an antenna shield that is substantially similar to theantenna shield 906 of FIG. 10, which includes twenty-four tilted slotsprovided with two dissimilar lengths of 7.5 in. and 4.125 in., and witha width of 0.188 in.

The data in table 1400 indicate that adding an antenna shield withtilted slots to the first antenna assembly results in a gain decrease,as shown by the data obtained from the second, third, and fourth antennaassemblies. The gain performance for the fourth antenna assembly,however, was largely superior to the gain performance of the second andthird antenna assembly designs, especially at higher frequencies (e.g.,8 kHz and 32 kHz). It can be concluded, then, that having two or moredissimilar lengths of slots (long and short) in an antenna shield canincrease the gain performance of a given antenna assembly whilesimultaneously maintaining the structural integrity of the antennashield.

FIG. 15 is a table 1500 showing comparative test results obtained fromtwo variations in antenna shield designs in conjunction with varying thedesign of the underlying soft magnetic band of an antenna assembly.Similar to table 1400 of FIG. 14, the antenna shield designs are againcompared against a dipole response for an air coil antenna, as shown inthe second column. Moreover, tests were again performed while excitingthe coil of a given antenna assembly at several frequencies: 500 Hz, 1kHz, 2 kHz, 8 kHz, and 32 kHz.

The antenna shield designs are also compared against two base antennaassembly designs, shown in the third column as a first antenna assemblyand a fourth antenna assembly. The first antenna assembly is the same asthe antenna assembly 402 of FIGS. 6A-6B, and is used as the base antennaassembly for the second and third antenna assemblies. The fourth antennaassembly is the same as the antenna assembly 702 of FIGS. 7A-7B, whichincludes the soft magnetic band having a plurality of stacked inserts,and is used as the base antenna assembly for the fifth and sixth antennaassemblies.

The second and fifth antenna assemblies each include an antenna shieldthat is substantially similar to the antenna shield 906 of FIG. 9, wherethe antenna shield has twenty-four tilted slots and each slot has thesame uniform length. The third and sixth antenna assemblies each includean antenna shield that is substantially similar to the antenna shield906 of FIG. 10, where the antenna shield has tilted slots provided withtwo dissimilar lengths (long and short).

The data in table 1500 provide a comparison of the gain performancebetween a base antenna assembly design with a conventional soft magneticband (i.e., the first through third antenna assemblies) and one withstacked inserts (i.e., the fourth through sixth antenna assemblies).Table 1500 indicates that the performance of the base antenna assemblydesign with the conventional soft magnetic band and without an antennashield (i.e., the first antenna assembly) is superior to the antennaassembly design with stacked inserts without an antenna shield (i.e.,the fourth antenna assembly). However, when the antenna shield isincluded, both antenna assembly designs exhibit substantially similarperformance at each frequency. This may prove useful for drillingoperations that require an antenna assembly to obtain measurements whiledrilling. Inclusion of the antenna shield in drilling operations may berequired to protect the coil from wear and damage caused by drillingdebris and movement of a drill string.

FIG. 16 is a table 1600 showing comparative test results obtained fromvariations in antenna assembly designs having stacked inserts of a softmagnetic band aligned and misaligned with the slots of an antennashield. Similar to tables 1400 and 1500 of FIGS. 14 and 15,respectively, the antenna shield designs are again compared against adipole response for an air coil antenna, as shown in the second column.Tests were performed while exciting the coil of the given antennaassemblies at several frequencies: 2 kHz, 4 kHz, 8 kHz, 16 kHz, 32 kHz,and 64 kHz.

Table 1600 provides comparative test data from first, second, third, andfourth antenna assemblies. Each antenna assembly includes a softmagnetic band comprising a plurality of stacked inserts, similar to theantenna assembly 702 of FIGS. 7A-7B. Moreover, each antenna assembly istested in conjunction with an antenna shield similar to the antennashield 906 of FIG. 10, where the tilted slots of the antenna shield areprovided with two dissimilar lengths (long and short). The antennashield used with the first and second antenna assemblies has twenty-fourtilted slots with two dissimilar lengths, and the antenna shield usedwith the third and fourth antenna assemblies has thirty-six tilted slotswith two dissimilar lengths. The data in Table 1600 also reflectsmeasurements obtained when the stacked inserts of the soft magnetic bandof each antenna assembly are misaligned or aligned with the tiltedslots. It is observed from the test results provided in Table 1600 thatwhen the stacked inserts are aligned radially with the tilted slots,such that the stacked inserts are exposed through the radially adjacenttilted slots, the gain performance of the particular antenna assembly issuperior as compared to the antenna assemblies where the stacked insertsare radially misaligned with the tilted slots.

FIG. 17 is a table 1700 showing comparative test results obtained fromvariations in antenna assembly designs having a soft magnetic bandcomprising stacked inserts with varying numbers of rods. Similar totables 1400, 1500, and 1600 of FIGS. 14-16, respectively, the antennashield designs are again compared against a dipole response for an aircoil antenna, as shown in the second column. Moreover, tests wereperformed while exciting the coil of the given antenna assemblies atseveral frequencies: 2 kHz, 4 kHz, 8 kHz, 16 kHz, 32 kHz, and 64 kHz.

Table 1700 provides comparative test data from first, second, third, andfourth antenna assemblies. Each antenna assembly includes a softmagnetic band comprising a plurality of stacked inserts, similar in somerespects to the antenna assembly 702 of FIGS. 7A-7B. Moreover, eachantenna assembly is tested in conjunction with an antenna shield,similar to the antenna shield 906 of FIG. 10, where the tilted slots ofthe antenna shield are provided with two dissimilar lengths (long andshort). The antenna shield used with the first and second antennaassemblies has twenty-four tilted slots with two dissimilar lengths, andthe antenna shield used with the third and fourth antenna assemblies hasthirty-six tilted slots with two dissimilar lengths.

In the testing, the number of stacked inserts and rods in the softmagnetic band of each antenna assembly was varied to determine itseffect on gain performance. The soft magnetic band of the first antennaassembly, for example, includes forty-eight stacked inserts, where eachstacked insert includes three rods. The soft magnetic band of the secondantenna assembly includes thirty-six stacked inserts, where each stackedinsert includes four rods. Consequently, the stacked inserts of thesecond antenna assembly are longer that the stacked inserts of the firstantenna assembly. The soft magnetic band of the third antenna assemblyincludes thirty-six stacked inserts, where each stacked insert includesthree rods. Lastly, the soft magnetic band of the fourth antennaassembly includes thirty-six stacked inserts, where each stacked insertincludes four rods. Consequently, the stacked inserts of the second andfourth antenna assemblies are longer that the stacked inserts of thefirst and third antenna assemblies.

It is observed from the test results provided in table 1700 that antennaassemblies having soft magnetic bands with longer stacked inserts (i.e.,second and fourth antenna assemblies) provide enhanced gain performanceover antenna assemblies having shorter stacked inserts (i.e., first andthird antenna assemblies). This is true with antenna assemblies having acomparable number of rods (i.e., 48×3=144; 36×4=144), and even were theshorter stacked insert pattern (i.e., 48×3) has denser rods.Accordingly, it may prove advantageous to stack the rods as long aspossible in a direction perpendicular direction with the coil in a givenstacked insert to improve performance.

Embodiments disclosed herein include:

A. An antenna assembly that includes a tool mandrel having a tool axis,a coil including a plurality of windings wrapped about the tool mandrel,wherein portions of the plurality of windings are wrapped about the toolmandrel at a winding angle offset from the tool axis, and a softmagnetic band radially interposing the coil and the tool mandrel andextending about a circumference of the tool mandrel, wherein the softmagnetic band includes a plurality of stacked inserts and each stackedinsert includes a plurality of rods positioned end-to-end.

B. A method that includes introducing a wellbore logging tool into awellbore, the wellbore logging tool including an antenna assembly thatincludes a tool mandrel having a tool axis, a coil including a pluralityof windings wrapped about the tool mandrel, wherein portions of theplurality of windings are wrapped about the tool mandrel at a windingangle offset from the tool axis, and a soft magnetic band radiallyinterposing the coil and the tool mandrel and extending about acircumference of the tool mandrel, wherein the soft magnetic bandincludes a plurality of stacked inserts and each stacked insert includesa plurality of rods positioned end-to-end. The method further includesobtaining measurements of a surrounding subterranean formation with thewellbore logging tool.

Each of embodiments A and B may have one or more of the followingadditional elements in any combination: Element 1: wherein the pluralityof rods comprises a material selected from the group consisting of aferrite, mu-metal, permalloy, metallic glass, and any combinationthereof. Element 2: wherein the soft magnetic band interposes the coiland the tool mandrel about the entire circumference of the tool mandrel.Element 3: wherein the plurality of rods in each stacked insertcooperatively forms a corresponding straight stacked insert that followsa curvature of an outer surface of the tool mandrel while extendingperpendicular to the coil. Element 4: wherein at least one rod of theplurality of rods has a length that is dissimilar to a length of otherrods of the plurality of rods. Element 5: wherein each rod comprises astraight, cylindrical member that exhibits a circular or polygonalcross-section. Element 6: further comprising a bobbin positioned aboutthe circumference of the mandrel, wherein the plurality of stackedinserts is positioned on the bobbin. Element 7: wherein the plurality ofstacked inserts is positioned on an outer radial surface of the bobbin.Element 8: wherein the plurality of stacked inserts is positioned on aninner radial surface the bobbin. Element 9: further comprising anantenna shield secured to the tool mandrel and positioned radiallyoutward from the coil, wherein the antenna shield defines a plurality ofslots extending perpendicular to the coil at any angular location aboutthe circumference of the tool mandrel. Element 10: wherein the pluralityof slots is provided in two or more dissimilar lengths. Element 11:wherein the plurality of stacked inserts are aligned radially with theplurality of slots. Element 12: wherein the plurality of stacked insertsare radially misaligned with the plurality of slots. Element 13: whereinthe soft magnetic band extends about the circumference of the toolmandrel at a band angle parallel to the winding angle. Element 14:wherein each stacked insert is positioned to extend perpendicular to awinding angle of the plurality of windings about the circumference ofthe tool mandrel.

Element 15: wherein the tool mandrel is operatively coupled to a drillstring and introducing the wellbore logging tool into the wellborefurther comprises extending the wellbore logging tool into the wellboreon the drill string, and drilling a portion of the wellbore with a drillbit secured to a distal end of the drill string. Element 16: whereinintroducing the wellbore logging tool into the wellbore furthercomprises extending the wellbore logging tool into the wellbore onwireline as part of a wireline instrument sonde. Element 17: wherein theantenna assembly further includes a bobbin arranged about thecircumference of the mandrel and the plurality of stacked inserts ispositioned on the bobbin. Element 18: wherein the antenna assemblyfurther includes an antenna shield secured to the tool mandrel andpositioned radially outward from the coil, wherein the antenna shielddefines a plurality of slots extending perpendicular to the coil at anyangular location about the circumference of the tool mandrel. Element19: wherein the plurality of slots is provided in two or more dissimilarlengths. Element 20: wherein the plurality of stacked inserts arealigned or misaligned radially with the plurality of slots.

By way of non-limiting example, exemplary combinations applicable to Aand B include: Element 7 with Element 8; Element 9 with Element 10;Element 9 with Element 11; Element 9 with Element 12; Element 18 withElement 19; and Element 18 with Element 20.

Therefore, the disclosed systems and methods are well adapted to attainthe ends and advantages mentioned as well as those that are inherenttherein. The particular embodiments disclosed above are illustrativeonly, as the teachings of the present disclosure may be modified andpracticed in different but equivalent manners apparent to those skilledin the art having the benefit of the teachings herein. Furthermore, nolimitations are intended to the details of construction or design hereinshown, other than as described in the claims below. It is thereforeevident that the particular illustrative embodiments disclosed above maybe altered, combined, or modified and all such variations are consideredwithin the scope of the present disclosure. The systems and methodsillustratively disclosed herein may suitably be practiced in the absenceof any element that is not specifically disclosed herein and/or anyoptional element disclosed herein. While compositions and methods aredescribed in terms of “comprising,” “containing,” or “including” variouscomponents or steps, the compositions and methods can also “consistessentially of” or “consist of” the various components and steps. Allnumbers and ranges disclosed above may vary by some amount. Whenever anumerical range with a lower limit and an upper limit is disclosed, anynumber and any included range falling within the range is specificallydisclosed. In particular, every range of values (of the form, “fromabout a to about b,” or, equivalently, “from approximately a to b,” or,equivalently, “from approximately a-b”) disclosed herein is to beunderstood to set forth every number and range encompassed within thebroader range of values. Also, the terms in the claims have their plain,ordinary meaning unless otherwise explicitly and clearly defined by thepatentee. Moreover, the indefinite articles “a” or “an,” as used in theclaims, are defined herein to mean one or more than one of the elementsthat it introduces. If there is any conflict in the usages of a word orterm in this specification and one or more patent or other documentsthat may be incorporated herein by reference, the definitions that areconsistent with this specification should be adopted.

As used herein, the phrase “at least one of” preceding a series ofitems, with the terms “and” or “or” to separate any of the items,modifies the list as a whole, rather than each member of the list (i.e.,each item). The phrase “at least one of” allows a meaning that includesat least one of any one of the items, and/or at least one of anycombination of the items, and/or at least one of each of the items. Byway of example, the phrases “at least one of A, B, and C” or “at leastone of A, B, or C” each refer to only A, only B, or only C; anycombination of A, B, and C; and/or at least one of each of A, B, and C.

What is claimed is:
 1. An antenna assembly, comprising: a tool mandrelhaving a tool axis; a coil including a plurality of windings wrappedabout the tool mandrel at a winding angle offset from the tool axis; anda soft magnetic band radially interposing the coil and the tool mandreland extending about a circumference of the tool mandrel at a band angleparallel to the winding angle, wherein the soft magnetic band includes aplurality of stacked inserts extending perpendicular to the coil aboutthe circumference of the tool mandrel and each stacked insert includes aplurality of rods positioned end-to-end, the soft magnetic bandconfigured to increase an inductance of the coil.
 2. The antennaassembly of claim 1, wherein the plurality of rods comprises a materialselected from the group consisting of a ferrite, mu-metal, permalloy,metallic glass, and any combination thereof.
 3. The antenna assembly ofclaim 1, wherein the soft magnetic band interposes the coil and the toolmandrel about the entire circumference of the tool mandrel.
 4. Theantenna assembly of claim 1, wherein the plurality of rods in eachstacked insert cooperatively forms a corresponding straight stackedinsert that follows a curvature of an outer surface of the tool mandrelwhile extending perpendicular to the coil.
 5. The antenna assembly ofclaim 1, wherein at least one rod of the plurality of rods has a lengththat is dissimilar to a length of other rods of the plurality of rods.6. The antenna assembly of claim 1, wherein each rod comprises astraight, cylindrical member that exhibits a circular or polygonalcross-section.
 7. The antenna assembly of claim 1, further comprising abobbin positioned about the circumference of the mandrel, wherein theplurality of stacked inserts is positioned on the bobbin.
 8. The antennaassembly of claim 1, wherein the plurality of stacked inserts ispositioned on an outer radial surface of the bobbin.
 9. The antennaassembly of claim 8, wherein the plurality of stacked inserts ispositioned on an inner radial surface the bobbin.
 10. The antennaassembly of claim 1, further comprising an antenna shield secured to thetool mandrel and positioned radially outward from the coil, wherein theantenna shield defines a plurality of slots extending perpendicular tothe coil at any angular location about the circumference of the toolmandrel.
 11. The antenna assembly of claim 9, wherein the plurality ofslots is provided in two or more dissimilar lengths.
 12. The antennaassembly of claim 9, wherein the plurality of stacked inserts arealigned radially with the plurality of slots.
 13. The antenna assemblyof claim 9, wherein the plurality of stacked inserts are radiallymisaligned with the plurality of slots.
 14. A method, comprising:introducing a wellbore logging tool into a wellbore, the wellborelogging tool including an antenna assembly that includes: a tool mandrelhaving a tool axis; a coil including a plurality of windings wrappedabout the tool mandrel at a winding angle offset from the tool axis; anda soft magnetic band radially interposing the coil and the tool mandreland extending about a circumference of the tool mandrel at a band angleparallel to the winding angle, wherein the soft magnetic band includes aplurality of stacked inserts extending perpendicular to the coil aboutthe circumference of the tool mandrel and each stacked insert includes aplurality of rods positioned end-to-end, the soft magnetic bandconfigured to increase an inductance of the coil; and obtainingmeasurements of a surrounding subterranean formation with the wellborelogging tool.
 15. The method of claim 14, wherein the tool mandrel isoperatively coupled to a drill string and introducing the wellborelogging tool into the wellbore further comprises: extending the wellborelogging tool into the wellbore on the drill string; and drilling aportion of the wellbore with a drill bit secured to a distal end of thedrill string.
 16. The method of claim 14, wherein introducing thewellbore logging tool into the wellbore further comprises extending thewellbore logging tool into the wellbore on wireline as part of awireline instrument sonde.
 17. The method of claim 14, wherein theantenna assembly further includes a bobbin arranged about thecircumference of the mandrel and the plurality of stacked inserts ispositioned on the bobbin.
 18. The method of claim 14, wherein theantenna assembly further includes an antenna shield secured to the toolmandrel and positioned radially outward from the coil, wherein theantenna shield defines a plurality of slots extending perpendicular tothe coil at any angular location about the circumference of the toolmandrel.
 19. The method of claim 18, wherein the plurality of slots isprovided in two or more dissimilar lengths.
 20. The method of claim 18,wherein the plurality of stacked inserts are aligned or misalignedradially with the plurality of slots.